3A Body Construction – Sedan Page 3A-1
Page 3A-1
Section 3A
Body Construction – Sedan
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to Section 2
Precautions in this Supplement and Section 00 Warnings, Cautions and Notes in the MY2005 VZ Service
Information for correct workshop practices with regard to safety and/or property damage.
The structure of the body shell has been
developed using complex design and
development techniques. In addition to
meeting all required standards, the vehicle
body is also a critical part of the overall safety
systems. It is therefore imperative the repair
procedures described here are adhered to
during all vehicle body repairs.
1 General Description ...............................................................................................................................2
2 Body Structure Panels...........................................................................................................................3
2.1 Front End and Underbody..................................................................................................................................... 4
2.2 Upperbody Structure, Excluding Roof Structure................................................................................................ 6
2.3 Roof Structure........................................................................................................................................................ 8
2.4 Body Structure....................................................................................................................................................... 9
3 Body Dimensions.................................................................................................................................11
3.1 Underbody Dimensions – Projected .................................................................................................................. 11
3.2 Upperbody Dimensions – Actual........................................................................................................................ 13
Front...................................................................................................................................................................... 13
Side and Interior................................................................................................................................................... 14
Rear....................................................................................................................................................................... 15
4 Body Margins........................................................................................................................................16
5 Body Sealing, Adhesives and Deadeners..........................................................................................19
5.1 Acrylic Spot Weld Sealer (Item 2)....................................................................................................................... 21
Acrylic Spot Weld Sealer (Item 2) Continued .................................................................................................... 22
5.2 Joint Sealer (Item 3)............................................................................................................................................. 23
Joint Sealer (Item 3) Continued.......................................................................................................................... 24
Joint Sealer (Item 3) Continued.......................................................................................................................... 25
Joint Sealer (Item 3) Continued.......................................................................................................................... 26
Joint Sealer (Item 3) Continued.......................................................................................................................... 27
Joint Sealer (Item 3) Continued and Hand Putty (Item 4) ................................................................................. 28
5.3 Adhesive – Anti Flutter (Item 5).......................................................................................................................... 29
5.4 Adhesive – Structural (Item 6) ............................................................................................................................ 30
5.5 Spray-on Deadener.............................................................................................................................................. 31
5.6 Deadener Panels and Insulators......................................................................................................................... 32
5.7 Fusible Reinforcement Patches.......................................................................................................................... 36
Replace................................................................................................................................................................. 36
6 Cavity Wax ............................................................................................................................................37
3A Body Construction – Sedan Page 3A-2
Page 3A-2
1 General Description
This Section contains body construction information specific to Sedan vehicles. For body construction information
relevant to all models, refer to Section 3 Body Construction.
The various sealers and adhesives used throughout the body are also described as it is imperative that only the correct
materials are used for repairs.
The correct cavity wax, deadeners a nd paint refinishing techniques are also imperative if the veh icle is to be returned to
its original condition.
When replacing or repairin g a part or sub-assembly, care must be taken to ensure that correct alignment and strength of
unit as a whole is maintained. In some instances, major damage to the body or frame can be repaired more effectively
and economically by replacing a part or sub-assembly with a new one, rather than repairing the damaged part.
A sunroof option is available that is fitted on the production line. To cater for this option, a unique roof structure is fitted
which features a housing asse mbly in place of the roof bow panels. A stainless steel front drain tube is al so fitted within
the hinge pillar cavity which effects the serv ice procedures for the hinge p illar, refer to Section 7A Body Side – Sedan
and Section 9A Roof – Sedan.
3A Body Construction – Sedan Page 3A-3
Page 3A-3
2 Body Structure Panels
The following tables and illustrations describe the body structure assemblies and panels that are available for service
replacement.
NOTE
Always refer to your Aut horised Retailer f or spare
parts availability configurations.
3A Body Construction – Sedan Page 3A-4
Page 3A-4
2.1 Front End and Underbody
Figure 3A – 1
3A Body Construction – Sedan Page 3A-5
Page 3A-5
Legend
1 Inner Rocker Panel Assembly, Right-hand / Left-hand
2 Seat Inner Bracket Assembly
3 Seat Outer Bracket Assembly, Right-hand / Left-hand
4 Front Floor Panel Assembly
5 Transmission Support Bracket, Right-hand / Left-hand
6 Front Floor Panel Extension
7 Front Side Rail Brace, Right-hand / Left-hand
8 Front Wheelhouse Panel Assembly, Right-hand / Left-hand
9 Horn Bracket Assembly, Left-hand only
10 Relay Housing Bracket, Right-hand only
11 ABS Modulator Bracket Assembly, Right-hand only
12 Battery Tray Assembly, Right-hand only
13 Front End Panel Assembly
14 Headlamp Panel, Left-hand / Right-hand
15 Headlamp & Front Fascia Mount Bracket, Left-hand / Right-
hand
16 Fender Front Lower Bracket, Left-hand / Right-hand
17 Radiator Lower Support Assembly
18 Front Side Rail Assembly, Left-hand / Right-hand
19 Radiator Side Mounting Bracket, Left-hand / Right-hand
20 Front Wheelhouse Bracket Assembly, Left-hand / Right-
hand
21 Front Bumper Impact Bar Bracket, Left-hand / Right-hand
22 Front Wheelhouse Panel Bracket, Left-hand / Right-hand
23 Rear Floor Panel Outer Extension, Left-hand / Right-hand
24 Rear Suspension Support Mount Plate, Left-hand / Right-
hand
25 Rear Tie Down Assembly, Left-hand / Right-hand
26 Rear Brake Hose Bracket, Left-hand / Right-hand
27 Rear Side Rail Assembly, Left-hand / Right-hand
28 Rear Bumper Impact Bar Brace Assembly, Left-hand / Right-
hand
29 Crossmember Assembly No. 2
30 Propeller Shaft Hanger Assembly
31 Rear Floor Panel Reinforcement, Left-hand
32 Rear Seat Belt Anchor Plate Assembly, Three places
33 Rear Floor Panel Assembly
34 Rear Floor Panel Reinforcement, Right-hand
35 Rear Compartment Floor Panel Outer Extension, Right-hand
36 Spare Wheel Anchor Plate Assembly
37 Fuel Tank Support Reinforcement Assembly
38 Rear Compartment Floor Panel Assembly
39 Rear Compartment Floor Panel Outer Extension, Left-hand
40 Rear End Panel Assembly
41 Rear End Panel Extension, Left-hand
42 Rear End Panel Extension, Right-hand
43 Rear End Lower Panel
3A Body Construction – Sedan Page 3A-6
Page 3A-6
2.2 Upperbody Structure, Excluding Roof
Structure
Figure 3A – 2
3A Body Construction – Sedan Page 3A-7
Page 3A-7
Legend
1 Hinge Pillar Trim Panel Bracket
2 Hinge Pillar Inner Panel Assembly
3 Front Wheelhouse Panel Upper Side Rail
4 Front Fender
5 Fender Lower Rear Bracket
6 Fender Rear Bracket
7 Door Opening Frame Assembly
8 Fender Upper Rear Bracket
9 Front Door Striker Anchor Plate
10 Rear Door Check Link Bracket
11 Rear Door Striker Anchor Plate
12 Underbody Jacking Locator
13 Rear Quarter Panel
14 Quarter Panel Lower Extension
15 Tail Lamp Housing
16 Wiring Harness Bracket
17 Quarter Panel Upper Extension
18 Rear Wheelhouse Inner Panel Assembly
19 Rear Seat Back Panel Extension
20 Rear Seat Back Panel Extension Assembly
21 Rear Window Panel Assembly
22 Rear Compartment Lid Strut Bracket Assembly
23 Tail Lamp Housing Brace
24 Fuel Filler Pipe Housing, Right-hand
25 Quarter Panel Inner Assembly
26 Sunroof Front Drain Tube*
27 Hinge Pillar Upper Reinforcement
28 Quarter Panel Inner Extension
* Shown for reference only, not serviced individually
3A Body Construction – Sedan Page 3A-8
Page 3A-8
2.3 Roof Structure
Figure 3A – 3
Legend
1 Roof Panel
2 Roof Front Header Panel
3 Roof Bow Panel
4 Roof Rear Panel
5 Roof Panel Assembly (With Sunroof)
3A Body Construction – Sedan Page 3A-9
Page 3A-9
2.4 Body Structure
Figure 3A – 4
3A Body Construction – Sedan Page 3A-10
Page 3A-10
Legend
1 Body Assembly
2 Dash Panel Assembly
3 Rear Compartment Lid Hinge Assembly
4 Rear Compartment Lid Assembly
5 Rear Bumper Impact Bar
6 Rear Bumper Impact Bar Bracket Assembly
7 Rear Door Assembly
8 Rear Door Outer Panel
9 Rear Door Hinge (Door Side)
10 Rear Door Hinge (Body Side)
11 Front Door Assembly
12 Front Door Hinge (Body Side)
13 Front Door Hinge (Door Side)
14 Front Door Outer Panel
15 Hood Hinge Assembly
16 Hood Assembly
17 Front Bumper Impact Bar Assembly
3A Body Construction – Sedan Page 3A-11
Page 3A-11
3 Body Dimensions
3.1 Underbody Dimensions – Projected
All dimensions are given in mm and are measured from the centre of hol es, on the outer side of the metal surface.
The main datum surface (1) is the underside of the front side rail assembl y, refer to Figur e 3A – 6.
The main datum hole (2) is a 19 mm hole on the underside of the front side rail assembly, refer to Figure 3A – 6.
The dash panel assembly attaching hole (3) in Figure 3A – 6 is the datum hole also depicted at View C in Figure 3A – 5.
Figure 3A – 5
3A Body Construction – Sedan Page 3A-12
Page 3A-12
Figure 3A – 6
3A Body Construction – Sedan Page 3A-13
Page 3A-13
3.2 Upperbody Dimensions – Actual
Front
Figure 3A – 7
3A Body Construction – Sedan Page 3A-14
Page 3A-14
Side and Interior
Figure 3A – 8
3A Body Construction – Sedan Page 3A-15
Page 3A-15
Rear
Figure 3A – 9
3A Body Construction – Sedan Page 3A-16
Page 3A-16
4 Body Margins
Figure 3A – 10
3A Body Construction – Sedan Page 3A-17
Page 3A-17
Figure 3A – 11
3A Body Construction – Sedan Page 3A-18
Page 3A-18
Figure 3A – 12
3A Body Construction – Sedan Page 3A-19
Page 3A-19
5 Body Sealing, Adhesives and
Deadeners
The commercially available products listed
below will meet the required standards. Other
products may be available that meet the
performance characteristics, however before
their use, the product manufacturer should be
contacted to check its suitability.
This Section details the sealers, adhesives and deadeners used in the Sedan body shell. It is imperative that the correct
materials are used and the directions on the product al ways be followed.
NOTE
When replacing any sealer, adhesive or
deadener, ensure the finish meets that of the
original application.
Weld Through Primer (Item 1)
Although not used in manufacture, Weld Through Primer is recommended for all service repair lap and flange joints
where Acrylic Spot Weld Sealer (Item 2) is not used. Weld Through Primer aids in corrosion protection of the joint.
Acrylic Spot Weld Sealer (Item 2)
Used in joints that require sealing additional to Joint Sealer (Item 3). It is applied to the joint flange prior to the mating of
panels. Refer to Figure 3A – 13 and Figure 3A – 14.
Joint Sealer (Item 3)
Primarily used for sealing joints to achieve a watertig ht seal. It seals notches, cut-outs and holes. Joint se aler should be
applied after priming, prior to application of the top coat. Refer to Figure 3A – 15 – Figure 3A – 20.
NOTE
• Figure 3A – 16, View E illustrates the
underside of the spare wheel-well. Following
priming, this area is sprayed with sealer
(rather than deadener) to a minimum
thickness of 2.5 mm and has a rough finish.
This procedure is important due to the
mounting of the fuel tank below it.
• During production a heat fusible patch is
applied along the joint of the back panel –
upper, refer Figure 3A – 18 View E. This
patch is not serviced as the heat required to
fuse it is beyond the capabilities of the
repairer. Joint sealer may be applied and
finished to produce a smooth surface.
3A Body Construction – Sedan Page 3A-20
Page 3A-20
Hand Putty (Item 4)
Hand putty, also known as caulking compound, is used in the areas marked * in Figure 3 A – 20.
Adhesive – Anti-Flutter (Item 5)
While used as a filler between an inner and outer panel to reduce panel flex, Anti-Flutter adhesive also aids rigidity and
assists in dispersing loads over a larger area. Refer to Figure 3A – 21 for locations.
Adhesive – Structural (Item 6)
Critical to the strength and rigidity of the vehicle, the correct adhesive must be used for service repairs. Using an
adhesive that is too weak will reduc e the performance of the joint. Using an adhesive that is too strong can also effect the
performance of the joint, compromising the ve hicle’s crash performance and safety system’s operation. This adhesive is
a 2-part system. Refer to Figure 3A – 22 for locations.
Spray-on Deadener (Item 7)
This deadener is spra yed onto the body shell after painting. It is used in the wheel-wells and on the under side of the
floor pan. A minimum thickness of 1.5 mm is required in these app lications. Refer to Figure 3A – 23 for locations.
Deadener Panels
Deadener panels are sold pre-cut as service parts. They are installed with the coloured side up and diamond embossed
side down. The panels are installe d prior to painting and some are heat fused to the bod y shell. Refer to Figure 3A – 24 –
Figure 3A – 30 for locations.
Commercially Available Sea ler, Adhesive and Deaden er Equivalents
Item No. Item Name Manufacturer Product Name
1 Weld Through Primer Refer to supplier –
2 Acrylic Spot Weld Sealer Lord (Fusor) Fusor #800 / #801
3 Joint Sealer Sprayable: Lord (Fusor)
Extruded beads: Lord (Fusor)
3M
Visible Seams
-self leveling: Lord (Fusor)
3M
-non sag: Lord (Fusor)
3M
Fusor #802
Fusor #800 / #801
Automix 8308
Fusor #122 / #125
Automix 8307
Fusor #123 / #126
Automix 8308
4 Hand Putty Lord (Fusor) Fusor #800 / #801
Automix 8307
5 Adhesive – Anti Flutter Lord (Fusor) Fusor #124
6 Adhesive – Structural (Two-Part) Lord (Fusor)
3M Fusor #108 B
Automix 8115
7 Spray-on Deadener Henkel Terophon 2000-13
NOTE
Special tools may be required to apply some
materials, refer to your supplier for further
information.
3A Body Construction – Sedan Page 3A-21
Page 3A-21
5.1 Acrylic Spot Weld Sealer (Item 2)
Figure 3A – 13
Legend
1 Door Opening Frame
2 Reinforcement – Hinge Pillar
3 Hinge Pillar Inner Panel
4 Closing Plate – Hinge Pillar
5 Front Wheelhouse Panel Upper Side Rail
3A Body Construction – Sedan Page 3A-22
Page 3A-22
Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3A – 14
3A Body Construction – Sedan Page 3A-23
Page 3A-23
5.2 Joint Sealer (Item 3)
Figure 3A – 15
3A Body Construction – Sedan Page 3A-24
Page 3A-24
Joint Sealer (Item 3) Continued
Figure 3A – 16
3A Body Construction – Sedan Page 3A-25
Page 3A-25
Joint Sealer (Item 3) Continued
Figure 3A – 17
3A Body Construction – Sedan Page 3A-26
Page 3A-26
Joint Sealer (Item 3) Continued
Figure 3A – 18
3A Body Construction – Sedan Page 3A-27
Page 3A-27
Joint Sealer (Item 3) Continued
Figure 3A – 19
3A Body Construction – Sedan Page 3A-28
Page 3A-28
Joint Sealer (Item 3) Continued and Hand Putty (Item 4)
Figure 3A – 20
3A Body Construction – Sedan Page 3A-29
Page 3A-29
5.3 Adhesive – Anti Flutter (Item 5)
Figure 3A – 21
3A Body Construction – Sedan Page 3A-30
Page 3A-30
5.4 Adhesive – Structural (Item 6)
Figure 3A – 22
3A Body Construction – Sedan Page 3A-31
Page 3A-31
5.5 Spray-on Deadener
Figure 3A – 23
3A Body Construction – Sedan Page 3A-32
Page 3A-32
5.6 Deadener Panels and Insulators
The deadener panels shown are heat fusible type. They are to be installed with the di amond embossed side down. Use a
heat gun, heat lamps or such to cure each deadener sheet.
Figure 3A – 24
Legend
1 Deadener – Front Floor, Right-hand
2 Deadener – Front Floor, Centre
3 Deadener – Front Floor, Left-hand
4 Deadener – Rear Floor, Right-hand
5 Deadener – Rear Floor, Centre
6 Deadener – Floor Rear, Left-hand
7 Deadener – Floor, Rear Seat Right-hand
8 Deadener – Floor, Rear Seat Left-hand
9 Deadener – Spare Wheel Well
A retainer (1) is used at five places to attach the dash panel lower insulator outer (2) to the engine compartment side of
the dash panel, refer to Figure 3A – 25.
3A Body Construction – Sedan Page 3A-33
Page 3A-33
Figure 3A – 25
The dash panel lower insulator inner (1) is attached to the
dash panel with two retainers (2).
Figure 3A – 26
The dash panel upper insu lator (1) is adhered to the dash
panel and care is required during removal. If required, apply
contact adhesive to the insulator prior to affixing it to the
new dash panel and ensure it follows the form of the dash
panel.
If a new insulator is being fitted, remove the backing paper
prior to fitting and apply.
Figure 3A – 27
3A Body Construction – Sedan Page 3A-34
Page 3A-34
The dash panel lower deadener (1) is a heat-fusible type.
Install it in position with the diamond embossed side to the
panel. Use a heat gun, heat lamps or such, to cure the
deadener. Smooth the deadener with a roller or such to
expel any air bubbles a nd to maximise adhesion.
Figure 3A – 28
The deadeners and insulators in Figure 3A – 29 and Figure 3A – 30 are self adhesive. Remove the backing paper and
attach the insulator ensuring a ny cut-outs align with brackets etc. Smooth the insulator firmly int o position.
NOTE
Ensure the notch in the rear s eat insulators (3) in
Figure 3A – 30 is aligned with the slot in the rear
seat ramp as shown A.
Figure 3A – 29
Legend
1 Insulator – Cowl Side, Left-hand
2 Deadener – Front Floor Extension, Left-hand 3 Deadener – Front Floor Extension, Right-hand
4 Insulator – Cowl Side, Right-hand
3A Body Construction – Sedan Page 3A-35
Page 3A-35
Figure 3A – 30
Legend
1 Insulator – Rear Seat Wheelhouse, Right-hand
2 Insulator – Rear Seat Wheelhouse, Left-hand 3 Insulator – Rear Seat
3A Body Construction – Sedan Page 3A-36
Page 3A-36
5.7 Fusible Reinforcement Patches
Two heat fusible reinforcing patches (1) are applied to the
front floor tunnel which provide stiffness and aid in the
reduction of Noise, Vibration and Harshness (NVH).
The sheets are pliable in their uncured state and ar e applied
to the vehicle prior to paint baking. The heat required to cure
and harden the sheets is approximately 120° C, and once
cured the sheets become a structural part of the vehicle.
Therefore, if the front floor assembly is replaced, the
patches must also be replaced.
Lower curing temperature replacement patches are
available from an Authorised Retailer.
Replace
1 Where possible, apply th e patches to the new floor
prior to painting.
2 Ensure the surface is clean, dry and free from weld
spatter, etc.
3 Apply the patches in the locations shown ensuring an
overlap of 5 – 10 mm (2).
4 Using a heat gun or dryi ng lamps, etc. evenly heat the
material until it smoothes and the edges begin to
‘soften’.
5 Smooth the material down with a roller or like, to
ensure no air bubbles are present and to maximise
adhesion.
6 Once cooled, the material should feel h ard.
Figure 3A – 31
3A Body Construction – Sedan Page 3A-37
Page 3A-37
6 Cavity Wax
The body and structural panels are constructed from high quality corrosion resistant materials. During manufacture,
cavity wax is applied to the ar eas shown to further increase the vehicle’s anti-corrosive properties.
Following repairs, to maintain the anti-corrosive properties of the vehicle, o nce the p aint is thoroughly dry apply cavity
wax to the areas shown below, and within any repaired box sect ions or areas inaccessible to paint. Refer to the table for
equivalent products to those used in manufacture.
Cavity Wax Equivalen ts
Item No. Equivalent Manufacturer Equivalent Product Name
8 Henkel
Terotex HV 8377/65
Nox Rust Hi-Wax 100B
Terasol 800113 (Aerosol pack)
Figure 3A – 32
3A Body Construction – Sedan Page 3A-38
Page 3A-38
Figure 3A – 33